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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
NASA NTRS2017

Improvements to Wire Bundle Thermal Modeling for Ampacity Determination

Abstract - Determining current carrying capacity (ampacity) of wire bundles in aerospace vehicles is critical not only to safety but also to efficient design. Published standards provide guidance on determining wire bundle ampacity but offer little flexibility for configurations where wire bundles of mixed gauges and currents are employed with various external insulation jacket surface properties. Thermal modeling has been employed in an attempt to develop techniques to assist in ampacity determination for these complex configurations. An earlier tool allowed analysis of wire bundle configurations but was constrained to configurations comprised of less than 50 elements. Additionally, for vacuum analyses, configurations with very low emittance external jackets suffered from numerical instability in the solution. A new thermal modeler is presented allowing for larger configurations and is not constrained by low bundle jacket surface infrared emittance calculations. Formulation of key internal radiation and interface conductance parameters is discussed including the effects of temperature and ambient air pressure on wire-to-wire thermal conductance. Test cases comparing model-predicted ampacity and that calculated from standards documents are presented.

Steven L Rickman↗
DOE OSTI2015

RRR and thermal conductivity of Ag and Ag0.2wt%Mg alloy in Ag/Bi-2212 wires

The residual resistivity ratio (RRR) and thermal conductivity of metal matrix in metal/superconductor composite wires are important parameters for designing superconducting magnets. However, the resistivity of silver in reacted Ag/Bi-2212 wires has yet to be determined over temperature range from 4.2 K to 80 K because Bi-2212 filaments have a critical transition temperature Tc of ~ 80 K, and because it is unknown whether the RRR of Ag/Bi-2212 degrades with Cu diffusing from Bi-2212 filaments into silver sheathes at elevated temperatures and to what degree it varies with heat treatment. We measured the resistivity of stand-alone Ag and AgMg (Ag-0.2wt%Mg) wires as well as the resistivity of Ag and Ag- 0.2wt%Mg in the state-of-the-art Ag/Bi-2212 round wires reacted in 1 bar oxygen at 890 °C for 1, 8, 24 and 48 hours and quickly cooled to room temperature. The heat treatment was designed to reduce the critical current Ic of Bi-2212 wires to nearly zero while allowing Cu loss to fully manifest itself. We determined that pure silver exhibits a RRR of ~ 220 while the oxide-dispersion strengthened AgMg exhibits a RRR of ~ 5 in stand-alone samples. A surprising result is that the RRR of silver in the composite round wires doesn’t degrade with extended time at 890 °C for up to 48 hours. This surprising result may be explained by our observation that the Cu that diffuses into the silver tends to form Cu2O precipitates in oxidizing atmosphere, instead of forming Ag-Cu solution alloy. We also measured the thermal conductivity and the magneto-resistivity of pure Ag and Ag-0.2 wt%Mg from 4.2 K to 300 K in magnetic fields up to 14.8 T and summarized them using a Kohler plot.

43 PARTICLE ACCELERATORS↗
DOE OSTI2018

Superconducting wires and methods of making thereof

Disclosed herein are superconducting wires. The superconducting wires can comprise a metallic matrix and at least one continuous subelement embedded in the matrix. Each subelement can comprise a non-superconducting core, a superconducting layer coaxially disposed around the non-superconducting core, and a barrier layer coaxially disposed around the superconducting layer. The superconducting layer can comprise a plurality of Nb.sub.3Sn grains stabilized by metal oxide particulates disposed therein. The Nb.sub.3Sn grains can have an average grain size of from 5 nm to 90 nm (for example, from 15 nm to 30 nm). The superconducting wire can have a high-field critical current density (J.sub.c) of at least 5,000 A/mm.sup.2 at a temperature of 4.2 K in a magnetic field of 12 T. Also described are superconducting wire precursors that can be heat treated to prepare superconducting wires, as well as methods of making superconducting wires.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2016

CFD Verification and Validation of Wire-Wrapped Pin Assemblies

TerraPower is participating in a cooperative project among industry, the national lab system, and academia to perform Verification and Validation (V and V) of Computational Fluid Dynamics (CFD) methods for predicting the flow and heat transfer within liquid-metal-cooled nuclear fuel assemblies with wire-wrapped fuel pins. This project, consisting of both experimental and numerical components, uses surrogate fluids and electrically heated fuel pins to substitute for the liquid metal coolant and the nuclear heat source. The experiments include both unheated assemblies to measure the flow velocities with Laser Doppler Velocimetry (LDV) and Particle Image Velocimetry (PIV), as well as heated assemblies to measure the temperatures of the fluid and the simulated fuel pins with thermocouples. Both sets of experiments also measure the pressure at multiple locations in the system. The numerical component of this work involves high-fidelity Large-Eddy Simulation (LES) modeling and industry-standard Reynolds-Averaged Navier-Stokes (RANS) modeling of the experiments. Furthermore, the experiments and simulations will be conducted on two duct geometries: the first is a non-deformed hexagonal duct that has flat internal duct faces that represents a beginning of life geometry. The other is a deformed duct where the internal hexagonal flow area enlarges then decreases along the axial height to represent the changes that occur to the duct geometry from pressure and irradiation effects in the core. This paper describes the methods and results of the industrial, RANS-based CFD code verification, solution verification, and solution validation. The V and V simulations are being performed for the following experiment test geometries: - Isothermal non-deformed bundle; - Heated non-deformed bundle; - Isothermal deformed bundle; - Heated deformed bundle. These flows have been computed at first with the pre-test design specifications, without the aid of any experimental results. Later, post-test calculations will be performed incorporating the actual test conditions and input from some of the experimental results. These RANS simulations of helically wire-wrapped fuel assemblies employ meshes of bare pins without the wire-wrap in the bundle. The effect of wire-wrap on the flow is accounted for by introducing a momentum source into the governing fluid equations. The momentum source is only applied to cells corresponding to the location of the wire-wrap, and its components in each cell are based on the local flow field. This methodology simplifies the geometry and mesh generation and reduces the cell count, while still capturing the effects of the wire-wrap. The momentum source approach is used for all of the assembly simulations performed in this study. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Advanced Manufacturing of Printed Melt Wire Chips for Cheap, Compact Passive In-Pile Temperature Sensors

Melt wires are a passive sensor used to determine peak temperatures during a test. Traditional melt wires are commonly used in test reactor experiments such as in the Advanced Test Reactor (ATR). However, the conditions within a reactor present significant challenges towards test design due to space limitations and the harsh environment. For example, some test capsules have only a couple millimeters in diameter available for instrumentation, which is too small to accommodate a traditional melt wire package, and they are ultimately filled to capacity when they are immersed in molten metal. To enable instrumentation for space limited applications, peak temperature sensing capabilities paired with additive manufacturing options have been utilized to develop printed melt wires for peak irradiation temperature detection. Here, we report on the fabrication of miniaturized melt wire chips with a melting temperature ~960 °C with printed silver nanoparticle ink. This study will advance the development of unique temperature sensors capable of sensing user specified temperature ranges within the harsh environment of irradiation testing.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2022

Wire-coil insert optimization for high-heat-load/flux synchrotron components

Many synchrotron components require high levels of internal-flow, forced-convection heat transfer to minimize surface temperatures, thermal gradients, and thermally induced stress on high-power beam-interacting surfaces. Wire-coil inserts, physically similar to a common spring, are mechanically fitted inside of component cooling passages to optimize heat transfer performance. They are routinely used in Advanced Photon Source (APS) front end and beamline high-heat-load/flux components to significantly enhance convection heat transfer-up to 400% compared to plain open passages. This has the additional benefit of greatly reducing coolant flow requirements for these components. Using several cooling passage sizes, five different wire sizes, and a range of pitch values, an experimental investigation conducted at the APS has determined the average heat transfer coefficient and resulting pressure loss as a function of water flow rate for 65 different wire-coil inserts. Data from this study have been non-dimensionalized and generalized to yield relationships that can be used to determine the heat transfer performance and resulting pressure loss for any given wire-coil insert that may be used at the APS. Through data reduction, the wire-coil insert characteristic dimensions have also been optimized to yield the highest heat transfer enhancement while minimizing the coolant flow requirements. These generalized expressions for wirecoil inserts will be presented, and they can be used by scientists and engineers during the component design process to evaluate achievable heat transfer performance and associated pressure loss, aiding in the establishment of optimized operating parameters and cooling passage flow distribution schemes.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

Hybrid additive manufacturing of AISI 316L via asynchronous powder and hot-wire laser directed energy deposition

Hybrid Additive Manufacturing (AM) offers a way to leverage the advantages of different AM technologies, enabling the efficient production of sizeable parts without compromising material properties or geometric complexity capabilities. This study presents an asynchronous hybrid Directed Energy Deposition (DED) strategy employing laser powder DED and laser hot-wire DED. AISI 316L parts comprising multiple powder and wire segments were fabricated with optional machining on AISI 316L substrates to investigate how quality is impacted by (i) alternative process sequences (laser powder DED followed by laser hot-wire DED and vice versa), (ii) machined vs. as-printed interfacial conditions, and (iii) material deposition on top vs. alongside previously built segments. Optical microscopy, X-ray computed tomography, and Vickers hardness were used to characterize the morphology and microstructure of the parts, localized porosity and lack of fusion defects, bulk density, and mechanical properties. Interfacial machining was necessary for dimensional control but promoted lack of fusion voids, resulting in a 99.71 ± 0.01% dense part. As-printed interfaces resulted in a denser part (99.82 ± 0.02%) at the expense of dimensional accuracy. The hardness of the parts with as-printed and machined interfaces was 196 ± 0.37 HV and 192 ± 0.40 HV, respectively, compared to 156 ± 1.4 HV for the substrate. Depositing powder alongside or on top of wire sections resulted in interfaces with a hardness of 217 ± 2.2 HV, compared to 185 ± 3.4 HV for the wire-powder interfaces.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Characterization and prediction of the electromechanical wear of contact tips during wire arc additive manufacturing of 316L stainless steel

Here, this study seeks to better understand the degradation of the contact tip with respect to WAAM for a 316L wire electrode as well as explore methods of monitoring the contact tip state from process data. The contact tip, a consumable component, positions the wire and serves as the electrical contact surface between the wire electrode and the welding power supply. The wear of the contact tip was characterized in terms of material loss and material contamination for a set of tips worn to discrete levels as measured by the amount of wire fed or arc time. Geometrical characterization found a 49% increase in the bore exit area at 180 meters of wire fed. Machine learning models were developed to predict the relative bore exit area of the contact tip from arc-based process data and a random forest classifier exhibited favorable performance with a cross-validated f1-score of 0.84. The regression architecture implemented a multi-layer perceptron with the ability to predict the relative exit area with an $R^2$ score of 0.75. Key features used in the prediction include the standard deviation of the voltage and the time between shorts.

Contact tip wear↗
DOE OSTI2024

Atomic-Scale Dynamic Mechanisms of Embedded MoS 2 Wires

Nanowires composed of a 1:1 stoichiometry of transition metals and chalcogen ions can be fabricated from two-dimensional transition metal dichalcogenides (TMDs) by using electron beam irradiation. Wires fabricated through in situ experiments can be geometrically connected to TMD sheets in various ways, and their physical properties can vary accordingly. Understanding the structural transformation caused by electron beams is critical for designing wire-sheet structures for nanoelectronics. In this study, we report the behavior of nanowires formed inside a monolayer MoS 2 sheet by combining phase-contrast images and large-scale atomistic modeling. Here we investigate the effect of vacancies on the dynamic evolution of wires, such as rotations with different edge structures and breaking, by considering the interactions between MoS wires and MoS 2 nanosheets. The obtained insights can be applied to other monolayer TMDs to guide the behavior of TMD wires and fabricate favorable geometries for various applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2015

A wire calorimeter for the SPIDER beam: Experimental tests and feasibility study

To study and optimize negative ion production and acceleration, in view of the use of neutral beam injectors in the ITER project, the SPIDER test facility (particle energy 100keV; beam current 50A, distributed over 1280 beamlets) is under construction in Padova, with the aim of testing beam characteristics and to verify the source proper operation, by means of several diagnostic systems. An array of tungsten wires, directly exposed to the beam and consequently heated to high temperature, is used in similar experiments at IPP-Garching to study the beam optics, which is one of the most important issues, in a qualitative way. The present contribution gives a description of an experimental investigation of the behavior of tungsten wires under high heat loads in vacuum. Samples of tungsten wires are heated by electrical currents and the emitted light is measured by a camera in the 400-1100nm wavelength range, which is proposed as a calibration tool. Simultaneously, the voltage applied to the wire is measured to study the dependency of emissivity on temperature. The feasibility study of a wire calorimeter for SPIDER is finally proposed; to this purpose, the expected behaviour of tungsten with the two-dimensional beam profile in SPIDER is numerically addressed.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2016

The transfer of atmospheric-pressure ionization waves via a metal wire

Our study has shown that the atmospheric-pressure He ionization waves (IWs) may be transferred from one dielectric tube (tube 1) to the other one (tube 2) via a floating metal wire. The propagation of IWs along the two tubes is not affected by the diameter of a floating metal wire, however, their propagation is strongly dependent on the length of a floating metal wire. The propagation of one IW along the tube 1 may result in the second IW propagating reversely inside the tube in vicinity of a floating metal wire, which keeps from their further propagation through the tube 1. After they merge together as one conduction channel inside the tube 1, the transferred plasma bullet starts to propagate along the tube 2. The propagation of transferred plasma bullets along the tube 2 is mainly determined by the capacitance and inductance effects, and their velocity and density can be controlled by the length of a floating metal wire.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2016

Observation of fast expansion velocity with insulating tungsten wires on ∼80 kA facility

This paper presents experimental results on the effects of insulating coatings on tungsten planar wire array Z-pinches on an 80 kA, 100 ns current facility. Expansion velocity is obviously increased from ∼0.25 km/s to ∼3.5 km/s by using the insulating coatings. It can be inferred that the wire cores are in gaseous state with this fast expansion velocity. An optical framing camera and laser probing images show that the standard wire arrays have typical ablation process which is similar to their behaviors on mega-ampere facilities. The ablation process and precursor plasma are suppressed for dielectric tungsten wires. The wire array implosion might be improved if these phenomena can be reproduced on Mega-ampere facilities.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2017

Construction and assembly of the wire planes for the MicroBooNE Time Projection Chamber

In this paper we describe how the readout planes for the MicroBooNE Time Projection Chamber were constructed, assembled and installed. We present the individual wire preparation using semi-automatic winding machines and the assembly of wire carrier boards. The details of the wire installation on the detector frame and the tensioning of the wires are given. A strict quality assurance plan ensured the integrity of the readout planes. The different tests performed at all stages of construction and installation provided crucial information to achieve the successful realization of the MicroBooNE wire planes.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2015

Analyses of Diamond Wire Sawn Wafers: Effect of Various Cutting Parameters

We have evaluated surface characteristics of diamond wire cut (DWC) wafers sawn under a variety of cutting parameters. These characteristics include surface roughness, spatial frequencies of surface profiles, phase changes, damage depth, and lateral non-uniformities in the surface damage. Various cutting parameters investigated are: wire size, diamond grit size, reciprocating frequency, feed rate, and wire usage. Spatial frequency components of surface topography/roughness are influenced by individual cutting parameters as manifested by distinct peaks in the Fourier transforms of the Dektak profiles. The depth of damage is strongly controlled by diamond grit size and wire usage and to a smaller degree by the wire size.

14 SOLAR ENERGY↗
DOE OSTI2019

High-Performance Bi-2212 Round Wires Made With Recent Powders

Multifilamentary Bi 2 Sr 2 CaCu 2 O x (Bi-2212) wire made by the powder-in-tube technique is the only high-temperature superconductor made in the round shape preferred by magnet builders. The critical current density (J C ) of Bi-2212 round wire was improved significantly by the development of overpressure heat treatment in the past few years. Bi-2212 wire is commercially available in multiple architectures and kilometer-long pieces and is a very promising conductor for very high-field NMR and accelerator magnets. Here, we studied the effects of precursor powder and heat treatment conditions on the superconducting properties and microstructure of recent Bi-2212 wires. Short samples of recent wire with optimized overpressure processing showed J C (4.2 K, 15 T) = 6640 A/mm 2 and J C (4.2 K, 30 T) = 4670 A/mm 2 , which correspond to engineering critical current densities J E (4.2 K, 15 T) = 1320 A/mm 2 and J E (4.2 K, 30 T) = 930 A/mm 2 .

36 MATERIALS SCIENCE↗
DOE OSTI2024

Effects of Rolling Reduction on Critical Current Density and Microstructure of Bi-2212 Wires

Bi-2212 Rutherford cables have been fabricated into flat racetrack coils and canted-cosine-theta dipole magnets. The performance gap between the magnets made with Rutherford cables and the “short-sample-limit” is about 30%. To better understand the influence of Rutherford cable processing on the strand performance, we studied three Bi-2212 wires with filament architectures of 37 × 18 and 55 × 18 and diameters of 0.8 and 1.0 mm. To simulate the deformation caused by cabling process, the three wires were rolled with thickness reductions ranging from 10% to 30%. The aspect ratios of rolled strands are between 1.29 and 2.05. The low aspect-ratio wire is also an interesting form for fabricating solenoid coils with higher packing density. The round and rolled strands were heat-treated under 50 bar and with maximum heat treatment temperatures of 885.5 °C and 890.5 °C. The rolling deformation reduced filament size uniformity, resulting in filament merging in fully heat-treated wires. It was found that rolling reduction reduced wire critical current density (JE) by 16 to 18%, but the JE decrease saturated at 15 to 20% of the thickness reduction. It is believed that the reduced JE results from the filament merging caused by rolling and non-uniform shrinking during overpressure heat treatment.

Bi-2212 wire↗
DOE OSTI2015

Substrate effect on nanoporous structure of silica wires by channel-confined self-assembly of block-copolymer and sol-gel precursors

Nanoporous silica wires of various wire diameters were developed by space-confined molecular self-assembly of triblock copolymer ethylene/propylene/ethylene (P123) and silica alkoxide precursor (tetraethylorthosilicate, TEOS). Two distinctive hard-templating substrates, anodized aluminum oxide (AAO) and track-etched polycarbonate (EPC), with channel diameters in the range between 10 nm and 200 nm were employed for space-confinement of soft molecular self-assembly driven by the block-copolymer microphase separation. It was observed in the scanning and transmission electron microscope (STEM) studies that the substrate geometry and material characteristics had pronounced effects on the structure and morphology of the silica nanowires. A substrate wall effect was proposed to explain the ordering and orientation of the intra-wire mesostructure. Circular and spiral nanostructures were found only in wires formed in AAO substrate, not in EPC. Pore-size differences and distinctive wall morphologies of the nanowires relating to the substrates were discussed. It was shown that the material and channel wall characteristics of different substrates play key roles in the ordering and morphology of the intra-wire nanostructures.

mesoporous wires↗
NASA NTRSDate not supplied

Towards Erecting Straighter Lightweight Towers on the Moon Using Deployable Guy Wires

This paper reports our static stability test findings for a simple guy wire system to correct the natural lateral deflections of an 8.5m tall, compact deployable composite tower intended to support exploration of lunar permanently shadowed regions by nearby robotic assets. Deployable composite booms with microgravity flight heritage are currently being investigated at NASA Langley Research Center (LaRC) and Massachusetts Institute of Technology(MIT)’s Space Resources Workshop for their potential to be vertically deployed in the lunar gravity field, in support of NASA’s Artemis campaign. These applications include vertical solar arrays and the provision of elevated lines-of-sight to science or engineering payloads on landers and rovers, in support of nearby or distant crewed or robotic assets exploring scientifically interesting and hard to reach areas. Useful elevated payloads include radio repeaters, remote sensing and imaging, navigation and power beaming systems. However, while these lightweight booms have an excellent height to mass ratio, they typically exhibit slight axial curvature upon deployment resulting in appreciable lateral dead-load deflection of the tip mass relative to the tower base. This static deflection increases with tower height and tip mass, not only constraining the value delivered by the tower but also endangering its integrity. To develop a competitive, lightweight deployable composite boom tower, a capability to correct static deflections during and after deployment may be required. This paper presents a pathfinder deployable guy wire stability system for the MIT / LaRC self-erecting composite boom lunar tower that provides real time measurements, maintains tension passively, and can serve as a reconfigurable platform to test new guy wire components, configurations and control algorithms. Using a validated, calibrated photogrammetry system, the natural lateral deflection of the boom tip relative to the boom base at different deployed heights in Earth’s gravity field was recorded. With real-time tension measurements it was found that guy wires can significantly reduce the tip deflection of a deployable composite boom under dead load. Specifically, we found that (1) control capability is greatest where it is needed most, i.e. for the lever arm closest to being opposite the direction of deflection, and (2) for a tower height of at least 8.5 m and arm length of at least 60 cm, a solution of differential tension in all three arms exists and, in principle, provides sufficient control capability to correct or significantly reduce boom deflections. We also found that natural deflections occur almost entirely out-of-plane of the seams of the boom cross-section, which was expected, and that the natural boom tip lateral deflection under dead load upon deployment was ~5% of boom deployed length, unexpectedly exceeding the manufacturing acceptance specification of 1%.Ongoing and future collaborative work between LaRC and MIT includes the further investigation of the unexpected lateral deflection, testing of alternative guy wire system designs at higher tensions and higher deployed heights, as well as trade studies of costs and benefits of an optimized integrated guywire system compared to other types of static stability solutions.

lunar towers↗